SINAMICS G120 Power Module PM240 Hardware Installation Manual · 07/2009 SINAMICS Answers for industry.
SINAMICS SINAMICS G120 Power Module PM240 Introduction 1 Safety notes 2 Installing/Mounting 3 Connecting 4 Service and maintenance 5 Technical specifications 6 Accessories 7 Appendix A Hardware Installation Manual Edition 07/2009 07/2009 A5E00807525B AD
Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.
Table of contents 1 Introduction................................................................................................................................................ 7 2 Safety notes............................................................................................................................................. 13 3 Installing/Mounting................................................................................................................................... 19 4 5 3.
Table of contents A 7.3 7.3.1 7.3.2 7.3.3 7.3.4 Braking Resistor........................................................................................................................ 107 Mounting the braking resistors.................................................................................................. 107 Connecting the braking resistor ................................................................................................ 113 Protecting the braking resistor ......................
1 Introduction The SINAMICS G120 range The SINAMICS G120 inverter has been designed for the accurate and efficient control of the speed and torque for three-phase motors. The SINAMICS G120 system comprises two basic modules, the Control Unit (CU) and the Power Module (PM).
Introduction Available Power Modules PM240 There are the following types of PM240 Power Modules with braking capacity (resistor braking). The given power rating values are defined for "high overload" operation. ● Unfiltered PM240 Power Modules 380 V … 480 V, IP20 or IPXXB, Frame size A … frame size GX, 0,37 kW … 200 kW ● PM240 Power Modules with integrated filter Class A 380 V … 480 V, IP20, Frame sizes B … F, 2,2 kW … 75 kW.
Introduction Block diagram PM240, FSA … FSF / / / 3( )XVH &RQWDFWRU /LQH UHDFWRU /LQH ILOWHU &RQWURO 8QLW ([WHUQDO RU LQWHJUDWHG LQ WKH 3RZHU 0RGXOH 8 9 : / / / 3RZHU 0RGXOH 8 9 : 3( '&3 5 5 %UDNLQJ UHVLVWRU 2XWSXW UHDFWRU RU VLQH ZDYH ILOWHU %UDNH 5HOD\ 3( 0 a 3RZHU VXSSO\ EUDNH Figure 1-1 RSWLRQDO DFFHVVRU\ Power Module PM240, frame size A … frame size F (HO 0.
Introduction Block diagram PM240, FSGX / / / 3( )XVH &RQWDFWRU /LQH UHDFWRU /LQH ILOWHU &RQWURO 8QLW 3 9 0 8 9 : / / / ; 3RZHU 0RGXOH 3( %UDNH FKRSSHU ; 8 9 : 2SWLRQDO FRQWDFWRU FRQWURO 5 5 %UDNLQJ UHVLVWRU 2XWSXW UHDFWRU RU VLQH ZDYH ILOWHU %UDNH 5HOD\ 3( 0 a 3RZHU VXSSO\ EUDNH Figure 1-2 10 RSWLRQDO DFFHVVRU\ Power Module PM240, frame size GX (HO 132 kW … 200 kW) Power Module PM240 Hardware Installation Manual, 07/200
Introduction Available technical documentation Comprehensive information and support tools are available from the Service and Support internet site ● http://support.automation.siemens.
Safety notes 2 Safety Instructions The following Warnings, Cautions and Notes are provided for your safety and as a means of preventing damage to the product or components in the connected machines. This section lists Warnings, Cautions and Notes, which apply generally when handling the inverter, classified as General, Transport and Storage, Commissioning, Operation, Repair and Dismantling and Disposal.
Safety notes General WARNING This equipment contains dangerous voltages and controls potentially dangerous rotating mechanical parts. Non-compliance with the warnings or failure to follow the instructions contained in this manual can result in loss of life, severe personal injury or serious damage to property. Protection in case of direct contact by means of SELV / PELV is only permissible in areas with equipotential bonding and in dry indoor rooms.
Safety notes CAUTION Children and the general public must be prevented from accessing or approaching the equipment! This equipment may only be used for the purpose specified by the manufacturer. Unauthorized modifications and the use of spare parts and accessories that are not sold or recommended by the manufacturer of the equipment can cause fires, electric shocks and injuries. NOTICE Keep this manual within easy reach of the equipment and make it available to all users.
Safety notes CAUTION Cable connection The control cables must be laid separately from the power cables. Carry out the connections as shown in the installation section in this manual, to prevent inductive and capacitive interference from affecting the correct function of the system. Mechanical Installation WARNING To ensure the safe operation of the equipment, it must be installed and commissioned by qualified personnel in full compliance with the warnings laid down in this manual.
Safety notes Operation WARNING The inverter operates at high voltages. When operating electrical devices, it is impossible to avoid applying hazardous voltages to certain parts of the equipment. The power supply and motor terminals - and if available the DC terminals - can carry dangerous voltages even if the inverter is inoperative. Wait five minutes to allow the unit to discharge after switching off the line supply before carrying out any installation work.
Safety notes Repair WARNING Repairs on equipment may only be carried out by Siemens Service, by repair centers authorized by Siemens or by authorized personnel who are thoroughly acquainted with all the warnings and operating procedures contained in this manual. Any defective parts or components must be replaced using parts contained in the relevant spare parts list. Disconnect the power supply before opening the equipment for access.
Installing/Mounting 3 WARNING To ensure the safe operation of the equipment, it must be installed and commissioned by qualified personnel in full compliance with the warnings laid down in this manual. Take particular note of the general and regional installation and safety regulations regarding work on dangerous voltage installation (e.g. EN 61800-5-1) as well as the relevant regulations regarding the correct use of tools and personal protective equipment (PPE).
Installing/Mounting 3.1 Air cooling requirements 3.1 Air cooling requirements Installation and cooling Make sure that there is an adequate airflow through the cubicle as follows: 1. Add the air flow values required for every Power Module (see following table) within the cubicle 2. Calculate the airflow required by components as reactor, filter, Control Unit and other electronic devices using the formula Air flow (l/s) = (Power loss (Watt) / ΔT) x 0.
Installing/Mounting 3.1 Air cooling requirements Air cooling requirements Table 3- 1 Air cooling requirements for operation with rated power (LO) Frame size LO power rating FSA FSB FSC Required cooling air flow I/s CFM 0.37 kW ... 1.5 kW 4.8 10 2.2 kW ... 4 kW 24 50 7.5 kW ... 15 kW 55 120 FSD 18.5 kW ... 30 kW 55 120 FSE 37 kW ... 45 kW 110 240 FSF 55 kW ... 132 kW 150 320 FSGX 160 kW ...
Installing/Mounting 3.2 Dimensions and drill pattern 3.2 Dimensions and drill pattern Dimensions, drill patterns and minimum distances The dimension drawings for all frame sizes for the SINAMICS G120 Power Module PM240 are shown in the figures and not true to scale. PP PP PP +HLJKW LQ FRPELQDWLRQ ZLWK WKH VFUHHQ WHUPLQDWLRQ NLW Z R %UDNH 5HOD\ PP LQFK 22 Figure 3-2 Dimensions and drill pattern, FSA (HO 0.37 kW ... 1.
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Installing/Mounting 3.2 Dimensions and drill pattern PP PP PP PP PP PP PP PP PP PP PP )RU IL[LQJ [ 0 EROWV [ 0 QXWV [ 0 ZDVKHUV 8VH ORFNLQJ HOHPHQWV 7LJKWHQLQJ WRUTXH 1P OEI LQ Figure 3-11 Dimensions and drill pattern, FSGX (HO 132 kW ... 200 kW) Table 3- 12 Minimum distances for mounting Minimum distances FSGX side by side 0 mm 0 inches above 250 mm 9.
Installing/Mounting 3.3 Control Unit installation 3.3 Control Unit installation Fitting the CU to the PM FSA ... FSF The Control Unit is snapped onto the Power Module as shown in the figure below. To disconnect the CU push the release button on top of the PM. The process of fitting the Control Unit to the Power Module is the same technique independent from the type of Control Unit or Power Module.
Installing/Mounting 3.3 Control Unit installation Fitting the CU to the Power Module FSGX The Control Unit is snapped inside the Power Module housing behind the front plate. 1. Unscrew the two fixing screws at the bottom of the front cover. 2. Push the cover upwards and remove it. 3. and 4. Snap the Control Unit onto the Power Module. 5HOHDVH EXWWRQ To disconnect the CU push the release button.
Installing/Mounting 3.3 Control Unit installation Adapting the CU frame of the Power Module front cover A plastic frame in the front cover of the Power Module ensures the IP20 or IPXXB protection class of the inverter.
4 Connecting Electrical Installation WARNING Power and motor connections A fixed location, non varying connection is necessary because of a leakage current > 3.5 mA. The inverter must always be grounded. If it is not grounded correctly, extremely dangerous conditions may arise which could prove potentially fatal. Isolate the mains electrical supply before making or changing connections to the unit. The terminals of the Inverter can carry dangerous voltages even if the inverter is inoperative.
Connecting 4.1 Power distribution systems 4.1 Power distribution systems Overview of Power Distribution Systems The power distribution systems described below, as defined in EN 60950 , have been considered in the design of the inverter. In the next figures three phase systems are outlined. The three phase inverter must be connected to L1, L2 and L3. PE must always be connected. The inverter will operate with most supply systems.
Connecting 4.2 Operation with ungrounded (IT) supplies 4.2 Operation with ungrounded (IT) supplies Operation with ungrounded (IT) supplies IT supplies are fully isolated from the protective earth system, usually by an isolating transformer. It should be noted, however, that a protective earth is still provided. WARNING Power Modules with built-in filters or external filters must not be used with IT supplies.
Connecting 4.3 Operation with Residual Current Devices (RCD) 4.3 Operation with Residual Current Devices (RCD) Operation with Residual Current Devices (RCD) If an RCD (also referred to as an ELCB or a RCCB) is fitted, the Power Module will operate without nuisance tripping provided that: ● A type B RCD is used. ● The trip limit of the RCD is 300 mA. ● The neutral of the supply is grounded. ● Only one Power Module is supplied from each RCD.
Connecting 4.4 Motor cable length and cross section 4.4 Motor cable length and cross section Permissible Cable Length The use of unshielded motor cables is possible. However to meet C2 EMI class, shielded cables with appropriate EMI installation are required.
Connecting 4.4 Motor cable length and cross section Table 4- 4 Cable cross section Frame size Cable cross section kW mm2 AWG Tightening torques Nm lbf in 0.37: 1.0 … 2.5 18 … 14 1.1 9.7 0.55: 1.0 … 2.5 18 … 14 1.1 9.7 0.75: 1.0 … 2.5 18 … 14 1.1 9.7 1.1: 1.0 … 2.5 18 … 14 1.1 9.7 1.5: 1.0 … 2.5 18 … 14 1.1 9.7 2.2: 1.5 … 6.0 16 … 10 1.5 13 3: 1.5 … 6.0 16 … 10 1.5 13 4: 2.5 … 6.0 14 … 10 1.5 13 5.5: 4.0 … 10 12 … 8 2.3 20 7.5: 4.0 … 10 12 … 8 2.
Connecting 4.4 Motor cable length and cross section CAUTION Cable cross section for grounding For power cables up to 10 mm² (Cu) or 16 mm² (Al) the earth cable must be at least as big as the power cables. For power cables larger than 10 mm² (Cu) or 16 mm² (Al) the earth cable must be at least 10 mm² (Cu) or 16 mm² (Al), but need not exceed these sizes.
Connecting 4.5 Access to power and motor terminals 4.5 Access to power and motor terminals Accessing the power and motor terminals Frame sizes A … C have no terminal covers. Frame sizes D … F terminal covers are accessed by the following steps, as shown in the figure below: 1. Release the latch on each side of the terminal covers with a suitable flat-bladed screwdriver 2. Push the cover upwards 3.
Connecting 4.5 Access to power and motor terminals The terminals of FSGX are accessed by removing the front cover: 1. Unscrew the two fixing screws at the bottom of the front cover 2.
Connecting 4.6 Power and motor connections 4.6 Power and motor connections Power and motor terminal layout The figures below show the layout of the power and motor terminals of the Power Module. The figure also includes the tightening torques for the terminals.
Connecting 4.6 Power and motor connections 6XSSO\ YROWDJH FRQQHFWLRQ 3( %UDNH FKRSSHU FRQQHFWLRQ : 9 8 '&3$ '&1$ 3( 8 9 : 0RWRU FRQQHFWLRQ Figure 4-3 Power and motor terminal layout for the FSGX M10 tightening torque: 25 Nm/18.4 lbf.
Connecting 4.7 DC 24V power supply connection (FSGX) 4.7 DC 24V power supply connection (FSGX) -X9: Terminal block The Power Module FSGX requires a separate DC 24V power supply. The power supply is connected to the X9 terminal block of the Power Module. Figure 4-4 Table 4- 5 -X9 terminal block ① on the Power Module FSGX Terminal block -X9 Terminal Function 1 P24V 2 M 3 Reserved, do not use 4 Reserved, do not use Technical specifications Voltage: 24 V DC (20.4 V - 28.
Connecting 4.8 Adjusting the fan voltage (FSGX) 4.8 Adjusting the fan voltage (FSGX) Fine-tuning the supply voltage of the fan The power supply for the device fan (1 AC 230 V) in the Power Module is generated from the line supply using a transformer. The transformer is fitted with primary taps so that it can be fine-tuned to the supply voltage. When delivered, the taps are always set to the highest level. With a low supply voltage, the appropriate transformer tap must be activated.
Connecting 4.9 Line contactor control (FSGX) 4.9 Line contactor control (FSGX) -X9: Terminal block The Power Module FSGX can control its line contactor. The control terminals for the line contactor are on the terminal block -X9. Figure 4-6 Table 4- 7 -X9 terminal block ① on the Power Module FSGX Terminal block -X9 Terminal 1 Function P24V Technical specifications Voltage: 24 V DC (20.4 V - 28.8 V) Current consumption: max.
Connecting 4.10 ESD guidelines 4.10 ESD guidelines Avoiding Electromagnetic Interference (EMI) The inverters are designed to operate in an industrial environment where a high level of EMI can be expected. Most installations do not give problems. However, it is good engineering practice to conform to the following guidelines - this will reduce the likelyhood of problems during operation.
Connecting 4.10 ESD guidelines Screening without a Screen Termination Kit In order to meet radiated emissions a screen termination kit must be used. Screening without a screen termination kit is only suitable for installation in a metal cabinet. Should a Screen Termination Kit not be available, the inverter then can be screened using the methodology shown in the figure below. This diagram shows both methodologies of screening. Note The EMI illustration below is not to scale.
Service and maintenance 5.1 5 Maintenance The purpose of maintenance is to preserve the specified condition of the Power Module. Dirt and contamination must be removed regularly and parts subject to wear replaced. The Power Module comprises mostly electronic components. Apart from the fan(s), the unit, therefore, contains hardly any components that are subject to wear or that require maintenance or servicing. The following points must generally be observed.
Service and maintenance 5.2 Replacing components 5.2 Replacing components Power Module spare parts Spare part available (✓) or not available (-) for Power Module ... FSA 0.37 kW ... 1.5 kW 52 FSB 2.2 kW ... 4 kW FSC 5.5 kW ... 11 kW FSD 15 kW ... 22 kW FSE 30 kW ... 37 kW FSF 45 kW ... 110 kW FSGX 132 kW ...
Service and maintenance 5.2 Replacing components 5.2.1 Replacing the cooling fan The service life of the cooling fan The average service life of the cooling fans is 50,000 hours. In practice, however, the service life may deviate from this value. Especially a dusty environment can occlude the fan. The fan must be replaced in good time to ensure that the inverter is available.
Service and maintenance 5.2 Replacing components Cooling fan replacement for FSD … FSF Preparatory steps ● Power-down the inverter ● Remove the Control Unit from the inverter ● Disconnect all the cables from the Power Module ● Place the Power Module face-down on a clean and safe surface Removal 1. Remove the fan retaining board 2. Release the fan cable connectors 3.
Service and maintenance 5.2 Replacing components Replacing the cooling fan FSGX Preparatory steps ● Disconnect the chassis unit from the power supply. ● Allow unimpeded access. ● Remove the protective cover.
Service and maintenance 5.2 Replacing components Removal The steps for the removal procedure are numbered in accordance with the diagram. 1. Remove the retaining screws for the fan (3 screws). 2. Disconnect the supply cables (1 x "L", 1 x "N"). You can now carefully remove the fan. CAUTION When removing the fan, ensure that you do not damage any signal cables. Installation For re-installation, carry out the above steps in reverse order.
Service and maintenance 5.2 Replacing components 5.2.
Service and maintenance 5.2 Replacing components Preparatory steps ● Disconnect the built-in unit from the power supply. ● Allow unimpeded access to the power block. ● Remove the protective cover. Removal The steps for the removal procedure are numbered in accordance with the diagram. 1. Unscrew the connection to the outgoing motor section (3 screws on the right side). Loose the 3 screws on the left side and turn the connection straps up. 2. Unscrew the connection to the line supply (3 screws). 3.
Service and maintenance 5.2 Replacing components Crane lifting lugs for secure transportation of the power block The power blocks are fitted with crane lifting lugs for transportation on a lifting harness in the context of replacement. The positions of the crane lifting lugs are illustrated by arrows in the figures below. WARNING A lifting harness with vertical ropes or chains must be used to prevent any risk of damage to the housing.
Service and maintenance 5.
Service and maintenance 5.2 Replacing components 5.2.
Service and maintenance 5.2 Replacing components Preparatory steps ● Disconnect the Power Module from the power supply. ● Allow unimpeded access. ● Remove the front cover. ● Remove the Control Unit. If necessary, remove the communication plugs and terminal wiring. Removal The steps for the removal procedure are numbered in accordance with the diagram. 1. Remove the two retaining screws for the Control Unit bracket. 2. Disconnect the cable from the Control Unit bracket to the CIM.
Service and maintenance 5.2 Replacing components CAUTION The connectors of the fiber-optic cables have to be mounted on their original plug-in position. The fiber-optic cables and the plug sockets are labelled accordingly (U11, U21, U31). Carefully re-establish the plug connections and ensure that they are secure. When dealing with connectors with a lock, make sure that the locking lever is securely engaged once connected. The screwed connections for the protective covers must only be tightened by hand.
6 Technical specifications Common performance ratings of the Power Module Table 6- 1 Performance ratings Feature Specification Line operating voltage 3 AC 380 V … 480 V ± 10% The permissible voltage depends on the operational altitude Input frequency 47 Hz … 63 Hz Power factor λ 0.7 ... 0.85 Overload capability for base load (HO) 0.37 kW ... 75 kW 1.
Technical specifications Feature Specification 160 kW ... 250 kW 0 °C … +40 °C (32 °F … 104 °F) Temperature range with derating Operational temperature up to 60° C (140° F) is possible with power derating Storage temperature -40 °C … +70 °C (-40 °F … 158 °F) Humidity < 95% RH - non-condensing In areas of high relative humidity, measures should be taken to ensure that condensation does not form within or around the SINAMICS G120.
Technical specifications Relationship between pulse frequency and output base-load current reduction Table 6- 2 LO base load Current reduction depending on pulse frequency Output base-load current at pulse frequency of 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 12 kHz 14 kHz 16 kHz kW A A A A A A A A 0.37 -- 1.30 1.11 0.91 0.78 0.65 0.59 0.52 0.55 -- 1.70 1.45 1.19 1.02 0.85 0.77 0.68 0.75 -- 2.20 1.87 1.54 1.32 1.10 0.99 0.88 1.1 -- 3.10 2.64 2.17 1.86 1.55 1.40 1.
Technical specifications Operating temperature derating The operating temperature range is shown diagramatically in the figures below: Permissible output base load current [%] High overload (HO) Permissible output base load current [%] Light overload (LO) 100 100 75 74 75 66 50 50 25 25 0 0 0 10 20 30 40 50 0 60 Ambient operating temperature [°C] Figure 6-1 10 20 30 40 50 60 Ambient operating temperature [°C] Current derating for temperature, FSA … FSF Permissible output base l
Technical specifications Operational altitude derating The figures below show the derating required according to altitude.
Technical specifications Power Module specifications CAUTION High Overload (HO) and Light Overload (LO) input currents The input current at the rated operating point - applies for the short-circuit voltage of the line supply Vk = 1% referred to the rated Power Module power and a rated line supply voltage of 400 V without a line reactor. If a line reactor is used, the specified values are reduced.
Technical specifications Table 6- 4 Order No. Frame Sizes A, 3 AC 380 V … 480 V, ± 10% unfiltered 6SL3224- 0BE21-1UA0 0BE21-5UA0 Rated power based on HOloading kW 1.1 1.5 hp 1.5 2 Power loss kW 0.108 0.114 Rated input current (HO) A 3.8 4.8 Rated output current (HO) A 3.1 4.1 Rated input current (LO) A 3.9 4.9 Rated output current (LO) A 3.1 4.1 Fuse A 10 10 Required cooling air flow l/s 4.8 4.8 CFM 10 10 mm2 1.0 … 2.5 1.0 … 2.5 AWG 18 … 14 18 … 14 kg 1.
Technical specifications Table 6- 6 Order No. Frame Sizes C, 3 AC 380 V … 480 V, ± 10% filtered 6SL3224- unfiltered 0BE25-5AA0 0BE27-5AA0 0BE31-1AA0 0BE25-5UA0 0BE27-5UA0 0BE31-1UA0 Rated power based on HOloading kW 5.5 7.5 11 hp 7.5 10 15 Power loss kW 0.240 0.297 0.396 Rated input current (HO) A 16.7 23.7 32.7 Rated output current (HO) A 13.2 19 26 Rated input current (LO) A 21.9 31.5 39.
Technical specifications Table 6- 8 Order No. Frame Sizes E, 3 AC 380 V … 480 V, ± 10% filtered 6SL3224- unfiltered 0BE33-0AA0 0BE33-7AA0 0BE33-0UA0 0BE33-7UA0 Rated power based on HOloading kW 30 37 hp 40 50 Power loss filtered kW 1.04 1.2 unfiltered kW 0.99 1.2 Rated input current (HO) 73 90 Rated output current (HO) 60 75 Rated input current (LO) 88 105 Rated output current (LO) 75 90 Fuse 100 125 Required cooling air flow 110 110 240 240 25.0 … 35.0 25.
Technical specifications Table 6- 10 Order No. Frame Sizes F, 3 AC 380 V … 480 V, ± 10% unfiltered 6SL3224- 0BE38-8UA0 0BE41-1UA0 Rated power based on HOloading kW 90 110 hp 125 150 Power loss kW 2.4 2.5 Rated input current (HO) A 205 235 Rated output current (HO) A 178 205 Rated input current (LO) A 234 284 Rated output current (LO) A 205 250 Fuse A 250 315 Required cooling air flow l/s Input cable / Output cable Weight Table 6- 11 Order No. 150.0 150.
7 Accessories Which accessory is available for which Power Module? Accessory available (✓) or not available (-) for Power Module … FSA 0.37 k W ... 1.5 kW FSB 2.2 kW ... 4 kW FSC 5.5 kW ... 11 kW FSD 15 kW ... 22 kW FSE 30 kW ... 37 kW FSF 45 kW ... 110 kW FSGX 132 kW ...
Accessories 7.1 Reactor and filter 7.1 Reactor and filter Line reactor The purpose of a line reactor is to reduce line-side harmonic currents and harmonic effects. This applies particularly in the case of weak power supplies (network short-circuit power uK > 1 %). Line filter The Power Module complies with a higher radio interference class when an additional line filter is used. Output reactor Output reactors reduce the voltage loading on the motor windings.
Accessories 7.1 Reactor and filter Connecting reactor and filter to the Power Module The following drawings show the connecting order of the power components. Shielded cables are necessary if a line filter (external or integrated) is used. Line fuses and contactor have to be installed between line reactor input and mains system.
Accessories 7.1 Reactor and filter Mounting base components Many system components for the Power Modules are designed as base components, that is, the component is mounted on the cabinet wall and the Power Module above it in a spacesaving construction. Up to two base components can be mounted above one another. Every further system component has to be mounted laterally.
Accessories 7.1 Reactor and filter 7.1.1 Line reactor Installing the line reactor as base component The line reactors for PM240 Power Modules of frame sizes FSA to FSE (0.37 kW … 37 kW) are designed as base components. The line reactor is attached to the mounting surface and the Power Module is mounted directly on the line reactor. The cables to the Power Module are already connected to the line reactor. The line reactor is connected to the line supply through terminals.
Accessories 7.1 Reactor and filter Installing the line reactor as lateral mounting component The line reactors for PM240 Power Modules of frame sizes FSF and FSGX (45 kW … 200 kW) have to be mounted laterally.
Accessories 7.1 Reactor and filter Table 7- 2 Technical specifications of the line reactors (table 1 of 6) Feature Suitable for Power Module with rated power (HO) of 0.37 kW ... 0.55 kW 0.75 kW ... 1.1 kW 1.5 kW FSA MLFB of the line reactor 6SE6400-3CC00-2AD3 6SE6400-3CC00-4AD3 6SE6400-3CC00-6AD3 MLFB of the suitable Power Module 6SL3224-0BE13-7UA0 6SL3224-0BE15-5UA0 6SL3224-0BE17-5UA0 6SL3224-0BE21-1UA0 6SL3224-0BE21-5UA0 11.5 mH 6.3 mH 3.2 mH 12.5/15 W 7.
Accessories 7.1 Reactor and filter Feature Suitable for Power Module with rated power (HO) of 2.2 kW ... 3 kW 4 kW 5.5 kW ... 7.5 kW FSB FSC Fixing dimensions Width Height 120 mm 200 mm 156 mm 232 mm Fixing screw 4 × M4 4 × M5 Weight 3.4 kg 3.4 kg Possible as base component Table 7- 4 5.2 kg yes Technical specifications of the line rectors (table 3 of 6) Feature Suitable for Power Module with rated power (HO) of 11 kW 15 kW ... 18.
Accessories 7.1 Reactor and filter Table 7- 5 Technical specifications of the line rectors (table 4 of 6) Feature Suitable for Power Module with rated power (HO) of 30 kW ... 37 kW FSE MLFB of the line reactor 6SL3203-0CJ28-6AA0 MLFB of the suitable Power Module 6SL3224-0BE33-0 . A0 6SL3224-0BE33-7 . A0 Inductance 0.
Accessories 7.1 Reactor and filter Feature Suitable for Power Module with rated power (HO) of 45 kW ...
Accessories 7.1 Reactor and filter 7.1.2 Line filter Installing the line filter as base component The line filters associated with the Power Modules of a rated power (HO) up to 11 kW are designed as base components. The line filter is attached to the mounting surface and the Power Module is mounted directly on the line filter. The cables to the Power Module are already connected to the line filter. The line filter is connected to the line supply through terminals.
Accessories 7.1 Reactor and filter Installing the line filter as lateral mounting component The line filters for Power Modules with a rated power (HO) of more than 11 kW and line filters from third party suppliers have to be mounted laterally.
Accessories 7.1 Reactor and filter Table 7- 8 Technical specifications of the line filters class A Feature Suitable for Power Module with rated power (HO) of 0.37 kW ... 1.5 kW 90 kW ... 110 kW 132 kW ...
Accessories 7.1 Reactor and filter Feature Suitable for Power Module with rated power (HO) of 0.37 kW ... 1.5 kW 2.2 kW ... 4 kW 5.5 kW ... 11 kW FSA FSB FSC Overall dimensions Width Height Depth 73 mm 200 mm 42.5 mm 153 mm 296 mm 50 mm 190 mm 362 mm 55 mm Fixing dimensions Width Height 56 mm 187 mm 120 mm 200 mm 156 mm 232 mm Fixing screw Weight Possible as base component 88 4 × M4 0.5 kg 4 × M5 1.5 kg 2.
Accessories 7.1 Reactor and filter 7.1.3 Output reactor Installing the output reactor as base component The output reactors for Power Modules with a rated power (HO) up to 11 kW are designed as base components. The output reactor is attached to the mounting surface and the Power Module is mounted directly on the output reactor. The cables to the Power Module are already connected to the output reactor. The output reactor is connected to the motor through terminals.
Accessories 7.1 Reactor and filter Installing the output reactor as lateral mounting component The output reactors for Power Modules with a rated power (HO) of more than 11 kW have to be mounted laterally. /LQH 8 9 : 3( 3RZHU 0RGXOH 8 9 : 3( 0RXQWLQJ VXUIDFH RU FDELQHW ZDOO 8 9 : 3( 2XWSXW UHDFWRU 8 9 : 3( 8 9 : 0RWRU Figure 7-7 3( 0 Connecting the output reactor as lateral component For more information see http://support.automation.siemens.
Accessories 7.1 Reactor and filter Table 7- 10 Technical specifications of the output reactors (table 1 of 6) Feature Suitable for Power Module with rated power (HO) of 0.37 kW ... 1.5 kW 2.2 kW … 4 kW 5.5 kW … 11 kW FSA FSB FSC MLFB of the line reactor 6SE6400-3TC00-4AD2 6SL3202-0AE21-0CA0 6SL3202-0AJ23-2CA0 MLFB of the suitable Power Module 6SL3224-0BE13-7UA0 6SL3224-0BE15-5UA0 6SL3224-0BE17-5UA0 6SL3224-0BE21-1UA0 6SL3224-0BE21-5UA0 6SL3224-0BE22-2 . A0 6SL3224-0BE23-0 .
Accessories 7.1 Reactor and filter Feature Suitable for Power Module with rated power (HO) of 15 kW 18.5 kW 22 kW FSD Fixing dimensions Width Height 70 mm 176 mm 94 mm 176 mm Fixing screw 4 × M6 Weight 10.5 kg 16 kg Possible as base component Table 7- 12 70 mm 176 mm 10.
Accessories 7.1 Reactor and filter Table 7- 13 Technical specifications of the output reactors (table 4 of 6) Feature Suitable for Power Module with rated power (HO) of 55 kW 75 kW 90 kW FSF MLFB of the line reactor 6SE6400-3TC15-4FD0 6SE6400-3TC14-5FD0 6SL3000-2BE32-1AA0 MLFB of the suitable Power Module 6SL3224-0BE35-5 . A0 6SL3224-0BE37-5 .
Accessories 7.
Accessories 7.1 Reactor and filter 7.1.4 Sine-wave filter Installing the sine-wave filter as base component The sine-wave filters for Power Modules with a rated power (HO) up to 11 kW are designed as base components. The sine-wave filter is attached to the mounting surface and the Power Module is mounted directly on the sine-wave filter. The cables to the Power Module are already connected to the sine-wave filter. The sine-wave filter is connected to the motor through terminals.
Accessories 7.1 Reactor and filter Installing the sine-wave filter as lateral mounting component The sine-wave filter for Power Modules with a rated power (HO) of more than 11 kW has to be mounted laterally. /LQH 8 9 : 3( 3RZHU 0RGXOH 8 9 : 3( 0RXQWLQJ VXUIDFH RU FDELQHW ZDOO 8 9 : 3( 6LQH ZDYH ILOWHU 8 9 : 3( 8 9 : 0RWRU Figure 7-9 3( 0 Connecting the sine-wave filter as lateral component For more information see http://support.automation.siemens.
Accessories 7.1 Reactor and filter Table 7- 16 Technical specifications of the sine-wave filters (table 1 of 5) Feature Suitable for Power Module with rated power (HO) of 0.37 kW ... 0.75 kW 1.1 kW … 1.5 kW 2.2 kW …3 kW FSA FSB MLFB of the sine-wave filter 6SL3202-0AE20-3SA0 6SL3202-0AE20-6SA0 6SL3202-0AE21-1SA0 MLFB of the suitable Power Module 6SL3224-0BE13-7UA0 6SL3224-0BE15-5UA0 6SL3224-0BE17-5UA0 6SL3224-0BE21-1UA0 6SL3224-0BE21-5UA0 6SL3224-0BE22-2 . A0 6SL3224-0BE23-0 .
Accessories 7.1 Reactor and filter Feature Suitable for Power Module with rated power (HO) of 4 kW Overall dimensions Width Height Depth 5.5 kW FSB FSC 153 mm 270 mm 100 mm 189 mm 336 mm 140 mm Installation clearance Top Bottom Side Fixing dimensions Width Height 100 mm 100 mm 100 mm 133 mm 258 mm Fixing screw 4 × M4 Weight 10.0 kg 167 mm 323 mm 4 × M5 12.0 kg Possible as base component Table 7- 18 7.5 kW … 11 kW 23.
Accessories 7.1 Reactor and filter Feature Suitable for Power Module with rated power (HO) of 15 kW … 18.
Accessories 7.
Accessories 7.2 Brake chopper (FSGX) 7.2 Brake chopper (FSGX) The function of the brake chopper The brake chopper controls the external braking resistor. ● The brake chopper is integrated in the Power Module FSA … FSF ● The Power Module FSGX does not contain a brake chopper.
Accessories 7.2 Brake chopper (FSGX) 7.2.1 Installing the Brake chopper (FSGX) The brake chopper is installed in a slot within the Power Module FSGX and force-cooled by its fan. The brake chopper is connected to the DC link by means of flexible cables, which are supplied as standard.
Accessories 7.2 Brake chopper (FSGX) Figure 7-12 Installing the brake chopper in a Power Module FSGX – steps 4 - 6 Installing the brake chopper The steps for the installation procedure are numbered in accordance with the figures in the diagrams. 1. Unscrew the 2 M6 screws from the front cover and lift off the cover. 2. Unscrew the 4 screws from the upper cover plate. Unscrew the 1 x M6 nut on the left-hand side and remove the front cover. 3. Unscrew the 4 screws from the upper cover plate.
Accessories 7.2 Brake chopper (FSGX) 6. Secure the connecting cable to the DC link with 2 screws (brake chopper connection) and 2 nuts (DC link connection). Carry out the subsequent steps in reverse order from steps 1 – 3. An opening above the connections for the braking resistor (R1, R2) is provided in the cover for connecting the cable to the braking resistor. CAUTION You must observe the tightening torques. Information on this can be found in the table in the "Mechanical installation" section 7.2.
Accessories 7.2 Brake chopper (FSGX) Connection overview %UDNH FKRSSHU 9 )DXOW RXWSXW 9 ,QKLELW LQSXW )DXOW 9 ,QKLELW %UDNLQJ UHVLVWRU 5 '&3$ &RQQHFWLRQ DW WKH '& OLQN &RQQHFWLQJ WKH EUDNLQJ UHVLVWRU '&1$ Figure 7-13 5 Connection overview of the brake chopper Digital input and output The connection of the digital input and output is not required for the function of the brake chopper.
Accessories 7.2 Brake chopper (FSGX) Threshold switch The response threshold at which the brake chopper is activated and the DC link voltage generated during braking are specified in the following table. WARNING The threshold switch must only be used when the Power Module is switched off and the DC link capacitors are discharged.
Accessories 7.3 Braking Resistor 7.3 Braking Resistor Braking resistor The braking resistor is designed for the SINAMICS G120 inverters with an internal brake chopper and enables loads with a large moment of inertia to be braked quickly. During braking of the motor and the load, excess energy is fed back to the inverter. This causes the voltage to rise in the DC link. The inverter transfers the excess energy to the externally mounted braking resistor. 7.3.
Accessories 7.3 Braking Resistor Braking resistor for Power Modules FSA and FSB (0.
Accessories 7.3 Braking Resistor Table 7- 23 Dimension data: Braking resistor, all data in mm and (inches) Order No. of the braking resistor 6SE6400-4BD11-0AA0 6SL3201-0BE12-0AA0 Suitable for Power Module (HO) FSA FSB 0.37 kW ... 1.5 kW 2.2 kW ... 4 kW 6SL3224-0BE13-7UA0 6SL3224-0BE15-5UA0 6SL3224-0BE17-5UA0 6SL3224-0BE21-1UA0 6SL3224-0BE21-5UA0 6SL3224-0BE22-2 . A0 6SL3224-0BE23-0 . A0 6SL3224-0BE24-0 . A0 L 230 (9.05) 239 (9.40) L1 217 (8.54) 226 (8.89) Order-No.
Accessories 7.3 Braking Resistor Braking resistor for Power Modules FSC … FSF (5.5 kW … 110 kW) Figure 7-15 110 Dimensions of the braking resistors, FSC ...
Accessories 7.3 Braking Resistor Table 7- 24 Dimension data: Braking resistor, all data in mm and (inches), Part 1 Order No. of the braking resistor 6SE6400-4BD165CA0 Suitable for Power Module (HO) FSC FSD FSE 5.5 kW ... 11 kW 15 kW ... 22 kW 30 kW ... 37 kW Order-No. of the suitable Power Module Table 7- 25 6SE6400-4BD212DA0 6SE6400-4BD222EA0 6SL3224-0BE25-5 . A0 6SL3224-0BE27-5 . A0 6SL3224-0BE31-1 . A0 6SL3224-0BE31-5 . A0 6SL3224-0BE31-8 . A0 6SL3224-0BE32-2 . A0 6SL3224-0BE33-0 .
Accessories 7.3 Braking Resistor Braking resistor for Power Module FSGX (132 kW … 200 kW) 7\SH SODWH [ 7KUHDGHG EROW 0 0 0 Figure 7-16 *URXQG FRQQHFWLRQ 0 7 7 6FUHZ WHUPLQDO PPt Dimensions of the braking resistor FSGX, order-no. 6SL3000-1BE32-5AA0 CAUTION A ventilation clearance of 200 m must be maintained on all sides of the braking resistor (with ventilation grilles).
Accessories 7.3 Braking Resistor 7.3.2 Connecting the braking resistor The braking resistor is connected at terminals DCP/R1 and R2. FSA ... FSF: The braking resistor can be connected directly to the Power Module. FSGX: The connecting of a braking resistor requires the installation of a brake chopper. On FSA to access the R1/R2- terminals the cutout cover must be removed using a small pair of cutters, ensuring that no plastics from the cutout fall into the inverter housing.
Accessories 7.3 Braking Resistor Figure 7-19 PM240 FSC spades Note With the cutout cover removed and no connections fitted to the spades, the inverter has only IP00 protection.
Accessories 7.3 Braking Resistor 7.3.3 Protecting the braking resistor Protecting the resistance The braking resistor must be protected against overheating. A thermostatic switch handles the protective function (this is supplied with each break resistor). One of the following two alternatives can be chosen to use this thermostatic switch for protecting the braking resistor: 1.
Accessories 7.3 Braking Resistor 2. Establish the power supply to the Power Module through a contactor which then shuts down the power supply when the resistor overheats. The thermostatic switch is connected in series with the coil feeder cable for the main contactor. The contacts of the thermostatic switch close again as soon as the resistor temperature has fallen below the selected value. Note The contactor is not part of the braking resistor option.
Accessories 7.3 Braking Resistor Resistor for Power Module ... FSA FSB FSC FSD Nominal power (HO) of the Power Module 0.37 kW ... 1.5 kW 2.2 kW ... 4 kW 5.5 kW ... 11 kW 15 kW ... 22 kW Order number 6SE64004BD11-0AA0 6SE64004BD12-0BA0 6SE64004BD16-5CA0 6SE64004BD21-2DA0 Thermoswitch (NC contact) maximum contact load connecting cable 250 VAC / 2.5 A 250 VAC / 2.5 A 250 VAC / 2.5 A 250 VAC / 2.5 A Weight 1.0 kg 1.6 kg 3.8 kg 7.
Accessories 7.4 Brake Relay 7.4 Brake Relay The Brake Relay is designed to provide the interface between the Power Module and the brake solenoid of a motor. There are two types of Brake Relays: ● Brake Relay – this provides the basic braking control function. ● Safe Brake Relay – this provides for the braking control function within a safety integrated system.
Accessories 7.4 Brake Relay Mounting the Brake Relay on Power Module FSGX The Brake Relay has to be mounted on the bracket above the Control Unit. 1. Mount the Brake Relay to the Control Unit bracket. 2. Connect the Brake Relay and the Power Module via the flying lead. 3. Connect the Brake Relay to the brake coil of the motor brake. Note The Safe Brake Relay requires an external 24V power supply.
Accessories 7.4 Brake Relay 7.4.2 Connecting the Brake Relay Connecting the Brake Relay to the Power Module Connect one end of the cable form to the Brake Relay. Two cable form with different lengths are provided with the Brake Relay. Choice the adequate length of the cable depending on the frame size of the Power Module and on the mounting location of the Brake Relay.
Accessories 7.4 Brake Relay Connecting the Brake Relay to the motor brake 3RZHU 0RGXOH 3RZHU VXSSO\ PRWRU EUDNH &75/ 0 a %UDNH 5HOD\ Figure 7-23 Brake Relay connection The Brake Relay has to be connected to protective earth, if the motor brake is supplied by a PELV circuit. Connecting the Safe Brake Relay to the motor brake The Safe Brake Relay can only control motor brakes with 24V power supply.
Accessories 7.4 Brake Relay 7.4.3 Technical specifications of the Brake Relay Brake Relay specifications Brake Relay Safe Brake Relay connected to the internal power supply of the Power Module DC 20.4 ... 28.8 V 1) Input current Max. conductor cross-section 2.5 mm² 2.5 mm² Degree of protection IP20 IP20 Switching capacity of the NO contact 1 AC 440 V, 3.5 A 1 DC 30 V DC, 12 A - Output voltage - 24 V Output current - max. 2 A Input voltage Max. 2.
Accessories 7.5 DIN rail mounting kit 7.5 DIN rail mounting kit Function The DIN rail mounting kit (DRMK) is designed to allow the SINAMICS G120 FSA and FSB inverters to be mounted on a pair of parallel DIN rails. The DRMK provides an integrated screening plate to allow for the termination of the screened motor cables and other screened cable used with the inverter. The DRMK for FSA allows for the mounting of either the inverter as a stand-alone or with the inverter and the footprint filter.
A Appendix A.1 Electromagnetic Compatibility Electromagnetic compatibility All manufacturers/assemblers of electrical apparatus which "performs a complete intrinsic function and is placed on the market as a single unit intended for the end user" must comply with the EMC directive EC/89/336.
Appendix A.2 Definition of the EMC Environment and Categories A.2 Definition of the EMC Environment and Categories Classification of EMC performance The EMC environment and categories are defined within the EMC Product Standard EN 61800-3, as follows: First Environment An environment that includes domestic premises and establishments that are connected directly to a public low-voltage power supply network without the use of an intermediate transformer.
Appendix A.2 Definition of the EMC Environment and Categories Category C3 Power Drive System (PDS) of rated voltage less than 1000 V intended for use in the Second (Industrial) Environment and not intended for use within the First (Domestic) Environment. Table A- 1 Compliance Table Model Remarks Category C1 - First Environment -- The inverters are not intended for use within the Category C1 Environment.
Appendix A.3 EMC Overall Performance A.3 EMC Overall Performance EMC Emissions The SINAMICS G120 drives have been tested in accordance with the emission requirements of the category C2 (domestic) environment. Table A- 2 Conducted & Radiated Emissions EMC Phenomenon Standard Level Conducted Emissions EN 55011 Class A Radiated Emissions EN 55011 Class A Note To achieve this performance the default switching frequency should not be exceeded.
Appendix A.
Appendix A.4 Standards A.4 Standards European Low Voltage Directive The SINAMICS G120 product range complies with the requirements of the Low Voltage Directive 2006/95/EC.
Appendix A.5 Abbreviations A.
Index A Accessing the power and motor terminals, 41 Air barrier, 20 Air cooling requirements, 21 Air flow, 20 Air short circuit, 20 B Base components, 78 Block diagram, 9, 10 Brake chopper installation, 101 Threshold switch, 104 X21 Terminal block, 104 Brake Relay, 116 Installing, 116 Technical specifications, 119 Braking resistor, 105 DIN rail mounting kit, 121 Drill pattern, 22 E Earth cable, 40 Electrical installation, 16, 35 Electromagnetic compatibility, 123 Electromagnetic Interference (EMI), 48 EM
Index Light Overload (HO) input currents, 68 Line contactor, 47 Line filter Installing, 76, 78, 84 Technical specifications, 86 Line reactor Installing, 76, 78 Technical specifications, 80 M Maintenance Cleaning, 51 Contamination, 51 Dirt, 51 Terminals, 51 Ventilation, 51 Mechanical installation, 16 Minimum distance above, 22 below, 22 front, 22 side by side, 22 O Operating temperature, 67 Operation with Residual Current Devices (RCD), 38 Operation with screened cables, 39 Operation with ungrounded suppl
Index T Technical construction file, 123 Technical specifications Brake Relay, 119 Braking resistor, 114 Line filter, 86 Line reactor, 80 Output reactor, 89 Power Module, 65 Sine-wave filter, 95 Temperature rise, 20 Terminal cover, 41 Tightening torque, 22, 43 TN-C, 36 TN-C-S, 36 TN-S, 36 TT, 36 U UL certified Fuses, 69 Underwriters Laboratories, 128 Unscreened cables, 39 X X21 Terminal block, 104 X47 connector, 118 X9 Terminal block, 45, 47 Power Module PM240 Hardware Installation Manual, 07/2009, A5E0
Siemens AG Industry Sector Drive Technologies Standard Drives Postfach 3180 91050 ERLANGEN GERMANY Subject to change without notice © Siemens AG 2009 www.siemens.
